ALT up grade to CS144D

[Pontiac1976]

The link where the talk started.>>> bowtieguy.proboards.com/thread/1289/coming-soon-alt-grade <<<


Upgrade Form SI ALT. to a CS 144D.

What I got and did. I bought a 2000 GMC SAVANA 4x2 3500 5.7L V8 gasoline 100 amp
(Note: you may need to lube or use Penetrating Lubricants for Rust) 4 screw bolts 5/16 might be E7
Take the 4 screw bolt out, pull apart. The bottom case has the stator attached to it.
take the pulley nut off 15/16 socket. There is lock washer a spacer the pulley,
Spacer front cover , spacer on top of the Rotor. Pull up out. pop frt. Side off
To take the stator, out 3 bolts wires from Stator the 11/32 nut driver.
Two upper bolt in the rectifier are ground to the case.
The other bolts are insulated make sure they all go back in the same places exact same way!
The voltage regulator is solder to the brush holder in the CS Alt’s. none like the SI Alt’s 70-80’s
Over the Yr’s I found that the spray tube you get with lube spray or use Penetrating Lubricants spray for Rust.
IE: PB, wd-40, and others work. The best for holding the brushes in the brush holder on all SI and CS.
For cleaning Rotor brush contact. 320-400 grit sandpaper or light grade scotch pad.

[Pontiac1976]

Vehicle Fits: What to find them in

Make, Model, Engine, Begin year - End Year

BUICK ROADMASTER 5.7L V8 1994 1996
CADILLAC ESCALADE 5.7L V8 1999 2000
CHEVROLET C1500 PICKUP 4.3L V6 1998 1998
CHEVROLET C1500 PICKUP 5.0L V8 1996 1999
CHEVROLET C1500 PICKUP 5.7L V8 1996 2000
CHEVROLET C1500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
CHEVROLET C1500 PICKUP 7.4L V8 1996 2000
CHEVROLET C2500 PICKUP 4.3L V6 1998 1998
CHEVROLET C2500 PICKUP 5.0L V8 1996 1999
CHEVROLET C2500 PICKUP 5.7L V8 1996 2000
CHEVROLET C2500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
CHEVROLET C2500 PICKUP 7.4L V8 1996 2000
CHEVROLET C3500 PICKUP 5.7L V8 1996 2000
CHEVROLET C3500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
CHEVROLET C3500 PICKUP 7.4L V8 1996 2000
CHEVROLET EXPRESS 1500 4.3L V6 1996 2000
CHEVROLET EXPRESS 1500 5.0L V8 1996 2000
CHEVROLET EXPRESS 1500 5.7L V8 1996 2000
CHEVROLET EXPRESS 2500 4.3L V6 1996 2000
CHEVROLET EXPRESS 2500 5.0L V8 1996 2000
CHEVROLET EXPRESS 2500 5.7L V8 1996 2000
CHEVROLET EXPRESS 2500 6.5L V8 DIESEL Turbocharged 1999 2000
CHEVROLET G10 4.3L V6 1996 1998
CHEVROLET G10 5.0L V8 1996 1998
CHEVROLET G10 5.7L V8 1996 1998
CHEVROLET G20 4.3L V6 1996 1998
CHEVROLET G20 5.0L V8 1996 1998
CHEVROLET G20 5.7L V8 1996 1998
CHEVROLET G20 6.5L V8 DIESEL 1997 1998
CHEVROLET G30 4.3L V6 1996 1998
CHEVROLET G30 5.7L V8 1996 1998
CHEVROLET G30 6.5L V8 DIESEL 1997 1998
CHEVROLET G30 7.4L V8 1996 1998
CHEVROLET K1500 PICKUP 4.3L V6 1998 1998
CHEVROLET K1500 PICKUP 5.0L V8 1996 1999
CHEVROLET K1500 PICKUP 5.7L V8 1996 2000
CHEVROLET K1500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
CHEVROLET K2500 PICKUP 4.3L V6 1998 1998
CHEVROLET K2500 PICKUP 5.0L V8 1996 1999
CHEVROLET K2500 PICKUP 5.7L V8 1996 2000
CHEVROLET K2500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
CHEVROLET K2500 PICKUP 7.4L V8 1996 2000
CHEVROLET K3500 PICKUP 5.7L V8 1996 2000
CHEVROLET K3500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
CHEVROLET K3500 PICKUP 7.4L V8 1996 2000
CHEVROLET LUMINA APV 3.4L V6 1996 1996
CHEVROLET LUMINA APV 3.8L V6 1992 1995
CHEVROLET SILVERADO 1500 4.3L V6 1998 1998
CHEVROLET SILVERADO 1500 5.7L V8 2000 2000
CHEVROLET SILVERADO 2500 5.7L V8 2000 2000
CHEVROLET SILVERADO 3500 5.7L V8 2000 2000
CHEVROLET TAHOE 5.7L V8 1995 2000
CHEVROLET TAHOE 6.5L V8 DIESEL Supercharged 1996 1999
GMC C1500 PICKUP 4.3L V6 1998 1998
GMC C1500 PICKUP 5.0L V8 1996 1999
GMC C1500 PICKUP 5.7L V8 1996 2000
GMC C1500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
GMC C1500 PICKUP 7.4L V8 1996 2000
GMC C2500 PICKUP 4.3L V6 1998 1998
GMC C2500 PICKUP 5.0L V8 1996 1999
GMC C2500 PICKUP 5.7L V8 1996 2000
GMC C2500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
GMC C2500 PICKUP 7.4L V8 1996 2000
GMC C3500 PICKUP 5.7L V8 1996 2000
GMC C3500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
GMC C3500 PICKUP 7.4L V8 1996 2000
GMC G10 4.3L V6 1996 1998
GMC G10 5.0L V8 1996 1998
GMC G10 5.7L V8 1996 1998
GMC G20 4.3L V6 1996 1998
GMC G20 5.0L V8 1996 1998
GMC G20 5.7L V8 1996 1998
GMC G20 6.5L V8 DIESEL 1997 1998
GMC G30 4.3L V6 1996 1998
GMC G30 5.7L V8 1996 1998
GMC G30 6.5L V8 DIESEL 1997 1998
GMC G30 7.4L V8 1996 1998
GMC K1500 PICKUP 4.3L V6 1998 1998
GMC K1500 PICKUP 5.0L V8 1996 1999
GMC K1500 PICKUP 5.7L V8 1996 2000
GMC K1500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
GMC K2500 PICKUP 4.3L V6 1998 1998
GMC K2500 PICKUP 5.0L V8 1996 1999
GMC K2500 PICKUP 5.7L V8 1996 2000
GMC K2500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
GMC K2500 PICKUP 7.4L V8 1996 2000
GMC K3500 PICKUP 5.7L V8 1996 2000
GMC K3500 PICKUP 6.5L V8 DIESEL Turbocharged 1996 2000
GMC K3500 PICKUP 7.4L V8 1996 2000
GMC SAVANA 1500 4.3L V6 1996 2000
GMC SAVANA 1500 5.0L V8 1996 2000
GMC SAVANA 1500 5.7L V8 1996 2000
GMC SAVANA 2500 4.3L V6 1996 2000
GMC SAVANA 2500 5.0L V8 1996 2000
GMC SAVANA 2500 5.7L V8 1996 2000
GMC SAVANA 3500 5.7L V8 1996 2000
GMC SAVANA 2500 6.5L V8 DIESEL Turbocharged 1999 2000
GMC SIERRA 1500 4.3L V6 1998 1998
GMC SIERRA 1500 5.7L V8 2000 2000
GMC SIERRA 2500 5.7L V8 2000 2000
GMC SIERRA 3500 5.7L V8 2000 2000
GMC YUKON 5.7L V8 1995 2000
GMC YUKON 6.5L V8 DIESEL Supercharged 1996 1999
OLDSMOBILE SILHOUETTE 3.4L V6 1996 1998
OLDSMOBILE SILHOUETTE 3.8L V6 1992 1995
PONTIAC TRANSPORT 3.4L V6 1996 1997
** The Front cover from Corvette ZR1 5.7L 1990-1995 is the cover you WANT, to work with any of the top list or the whole CS144 ALT for one or the CAMARO 5.7L 1996-2000 .

[Pontiac1976]

(The late Model Bottom case are the better ones with the rear bearing cut out showing the rear steel end cap of the bearing)

>>>>>> bearings in most cases will be for the Frt. 63034N Type NTN Brand Ball Bearing Double Sealed

Dimensions: 17mm ID x 47mm OD x 14mm.The rear is 8122 INA Brand Needle Bearing For Delco CS144 Late Style,

 
124 - 140 Amp Alternators. For Rear Housing (SRE Slip Ring end) 8121 Inner Race For Delco type Late Style CS144 Series

Alternators (Rotor)if needed . 461509 FRT. Bearing Retainer - Drive End. Frame if needed. To loosen Red Lock-Tight

use Nail Polish on the top frt. Bearing let it sit for 10 min. tap back the edge around the bearing race with a flat

punch to let it come out easier. Take the pulley put on top of a vise put the top cover center of the pulley take a

3/4” impact socket tap down bearing should pop out. Too pop out the rear bearing 1” 1/2 12 point

chrome socket on the back side so the rear bearing be in the center of the opening take a 1/2“ extension fat

side on bearing race tap out the bearing. Re-re-bearings Frt. Case in stove @ 300F 20min take out, take bearing

coat the hole outside race with RED LOCK-Tight should pop in if needs a little help tap on the outside race.

For the rear heat the case in stove @ 300F 20min freeze the bearing 12min re & re in revers with a little oil on

 
The outside on the bearing

[Pontiac1976]

CS 144D Parts list:   I had bought Brush kit-391083, **Rectifier -DR5176PF, Rotor- 28133,   I need FRT. Cover -21140 for late for style CS144 Alternators 12:00, 10mm Mounting Ear D.E. Frame Front Housing fits late 73-87 will also fit early style as well with new bracket.

Other Supply you should have.>>

Dielectric grease:

Electric parts cleaner:

High Heat Synthetic Grease:

How to make this fit the 73-87 truck years

V

V

V

V

V

v

[Pontiac1976]

This fits the stock location right side truck. You need factory mounting bracket SBC upper lower.

The upper mount to the ALT and the Intake FRT, Water pump FRT, the lower to the lower Water pump and the throw the ALT to Block.

Now you have to remove your old pulley on 73-85 with v belt pulleys Re-Use it, same on 84-86 that had the v belt pulley option.

On the 84-87 w/ the serpentine belt option should be able to use the serpentine pulley that came with it.

The FRT. Cover on the CS144 comes with two styles I seen. One you need has mounts two FRT,

Mounts straight across from each other . The other you do not want need to change is two mounts FRT,

One @ 12 o-clock and one @ 9 o-clock or it could be one @ 6 o-clock one @ 3 o-clock not needed.

This works with a stock GM intake of a 84 SS Mont Carlo & should work with most intakes “but you may have to sand few mm

down or Get a few MM thicker spacer for your Intake”.

I take two flat washers thickness is ( 2.5mm and 2.7mm ) put then under the bracket mount @ the intake. Then you have to weld washers the thickness

Of the same bracket we working on lower mounting area that mounts to the water pump to make it longer then cut the slot out

On the same angle so it adjustable. The thickness is ( 2.7mm and ) length is about ( 10.5 ) @ the end. .

Now the lower spacer can be used but needs extra spacer of thickness ( ) or make a new one length ( 85.2mm ) . The lower spacer

Can be made out of Alloy keep weight off. I like the cheap motor pulley grinder, compressor, same size as the Alt shaft because there

Deeper lighter work well. As I know I used one two years shift the car 7200 RPM’s two shifts, this pulley works just like the factory one.

Wiring you hook up the wire adapter to the old two plug to the new ALT plug run a 2GA or 4GA + bolt to the + side of the BATT post.

You may or may not have to run one size smaller belt.

[Pontiac1976]

The Wire Adapter plug for the Alternator (CS -Series) to GM (SI -Series) Alternator. Used on Vehicles with out alternator Warning light or if vehicle has Gauges . #12102921, #90196375,from 1988-1995 (Pico #5367-11 in Canada). There  are more places & part # late60's to early 90's.

[Pontiac1976]

just slide the straw in out of the way as you need. Then you can reuse it on lube can again and easier to grab.

Oh the clocking of the ATLERNATOR is with the back cover 4 pin plug between

7 & 8 O-clock area. The front cover thick side mount is @ 8 O-clock the thin side will be @ 2 O-clock

[Pontiac1976]

Extra Tools that Nice to Have:

A press of some type to press the bearings in:

Some Plastic or Wood spacers:

So you do not mess up the painted finish or a used Front bearing

This is a must **Batt impact gun/ air impact gun**

to get the Pulley nut off fast & easy.


As long as there Good, Case in good shape not leaking anything,

very smooth rolling.

The Cheap Pulley Up Grade for V Belt cars:

I use these pulley cut the back off at the height needed bolt it on there light easy polish if you want,

Paint, or leave it, or Polish it to a high luster.

The center can be a little bigger but the washer and nut have to cover the hole.

Some have lock washer some do not so it depends on the Alt. pulley set

[Pontiac1976]

**** This from the board " 67-72chevytrucks.com posted by ETsC10 forum staff member" Very Kool Big Thanks




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